Aerosol dispenser with vented valve cup and valve cup therefor

ABSTRACT

An aerosol dispenser, and a valve cup for an aerosol dispenser. The aerosol dispenser, has an outer container with a crimp ring, to receive a valve cup clinched thereto. The valve cup has an outer wall with holes therethrough or vents having a vector component parallel to the outer wall. The hole or vents may be exposed to pressurized propellant and product due to deformation of the neck during undue internal pressurization. The holes and vents relieve propellant and product therethrough in the event of overpressurization.

FIELD OF THE INVENTION

The present invention relates to aerosol dispensers having an integralvalve cup vent, and the valve cup to make such an aerosol dispenser.

BACKGROUND OF THE INVENTION

Aerosol dispensers are well known in the art. Aerosol dispenserstypically comprise an outer container which acts as a frame for theremaining components and as a pressure vessel for propellant and productcontained therein. Outer containers made of metal are well known in theart. However, metal containers can be undesirable due to high cost andlimited recyclability. Attempts to use plastic have occurred in the art.Relevant attempts in the art to employ plastic in aerosol dispensers arefound in U.S. Pat. Nos. 2,863,699; 3,333,743; 9,296,550; 9,334,103 and2009/0014679.

The outer containers are typically, but not necessarily, cylindrical.The outer container may comprise a closed end bottom adjoining thesidewalls and for resting on horizontal surfaces such as shelves,countertops, tables etc. The bottom of the outer container may comprisea re-entrant portion as shown in U.S. Pat. No. 3,403,804 or base cup asshown in U.S. Pat. No. 9,061,795. Sidewalls defining the shape of theouter container extend upwardly from the bottom to an open top.

The open top defines a neck for receiving additional components of theaerosol dispenser. The industry has generally settled upon a nominalneck diameter of 2.54 cm, for standardization of components amongvarious manufacturers, although smaller diameters, such as 20 mm, arealso used. Various neck shapes are shown in U.S. Pat. Nos. 6,019,252;7,028,866; 7,279,207 and 7,303,087.

Typically a valve cup is inserted into the neck. The valve cup is sealedagainst the neck to prevent the escape of the propellant and loss ofpressurization, such as described in U.S. Pat. Nos. 8,074,847;8,096,327; 8,844,765 and 8,869,842. The valve cup holds the valvecomponents which are movable in relationship to the balance of theaerosol dispenser. Suitable valves are shown in commonly assigned U.S.Pat. Nos. 8,511,522 and 9,132,955. When the valves are opened, productmay be dispensed through a nozzle, etc. as described in commonlyassigned U.S. Pat. No. 9,174,229.

A valve may be inserted into the valve cup for selective actuation bythe user. The valve is typically normally closed, but may be opened tocreate a flow path for the product to ambient or a target surface. Thevalve may be compatible with local recycling standards. Suitable valvesare disclosed in commonly assigned U.S. Pat. Nos. 8,511,522 and9,132,955.

If a valve is to be assembled into an aerosol, typically the valve cupis crimped onto the neck of the aerosol container. But this operation isexpensive and is difficult to perform with a plastic valve cup. Aseparate interlock may be used to attach a valve to a valve cup,particularly a plastic valve and plastic valve cup are used. Suitableinterlocks include bayonet fittings and threads as disclosed in commonlyassigned P&G application, Case 14458, Ser. No. 15/235,237, filed Aug.12, 2016. A pressure vessel with a threaded bore is proposed in U.S.Pat. No. 8,505,762.

A bag may be used to contain product for selective dispensing by a user.Dispensing of product from the bag occurs in response to the useractuating the valve. The bag separates product within the bag frompropellant disposed between the bag and container. This bag limits oreven prevents intermixing of the contents of the bag and the componentsoutside of the bag. Thus, product may be contained in the bag.Propellant may be disposed between the outside of the bag and the insideof the outer container. Upon actuation of the valve, a flow path out ofthe bag is created. This embodiment is commonly called a bag in can andmay be used, for example, in dispensing shaving cream gels.Alternatively, a bag may be directly joined to the valve housing, in aconfiguration commonly called a bag on valve. A suitable bagconfiguration is disclosed in commonly assigned application, P&G Case14458, Ser. No. 15/235,227, filed Aug. 12, 2016 which teaches attachinga bag to a valve cup.

If a bag configuration is desired, propellant may be disposed betweenthe bag and outer container, as disclosed in commonly assigned U.S. Pat.Nos. 8,631,632 and 8,869,842. Afterwards, product fill may occur in aseparate, remote, operation, optionally carried out in another location,which may be in the same country or in a different country. Such amanufacturing process can conserve costs in production, shipment and/orstorage.

An aerosol container having a bag therein may be made from a dual layerpreform, having plural layers disposed one inside the other. Relevantattempts include U.S. Pat. Nos. 3,450,254; 4,330,066; 6,254,820; RE30093 E; and publications WO 9108099 and US 2011/0248035 A1. But each ofthese attempts requires a separate operation to attach the bag to therelevant component. Each attachment step takes time in manufacturing andcreates the opportunity for leakage if not correctly performed.Improvements in dual layer preforms are found in commonly assignedapplication P&G Case 14461, application Ser. No. 15/235,279, filed Aug.12, 2016.

Alternatively, a dip tub may be used if intermixing of the product andpropellant is desired. When the user actuates the valve, the product andpropellant are dispensed together through the dip tube. Oneconfiguration is shown in commonly assigned U.S. Pat. No. 6,039,222.This embodiment may utilize a dip tube. The dip tube takes the productand propellant mixture from the bottom of the outer container. Or apiston may be used to expel product, if it is particularly viscous, asdescribed in commonly assigned US publication 2016/0368633.

But aerosol dispensers have typically been used to dispense productswhich can be used independent of the product temperature. For example,aerosol dispensers are commonly used to dispense cleaning products,insecticide, air fresheners, shaving cream, etc. These products areubiquitously dispensed at the temperature ambient to the aerosoldispenser, typically room temperature.

But room temperature may not be optimum for all products. Some productsmay be more optimally used in a warmed or heated condition, the termsbeing used interchangeably. For example, certain foods are morepalatable when served warm. Air freshener may disperse better whenwarmed. Shaving cream may be perceived to be more comfortable whenwarmed. Commonly assigned applications, P&G Case 14735, application Ser.No. 15/444,354 and P&G Case 14736, Ser. No. 15/444,356 disclose heatingof aerosol dispensers in a microwave oven.

Overpressurization, and rupture may occur, for example, during microwaveheating if a microwavable aerosol is left unattended or duringmanufacture if excessive propellant charge occurs. U.S. Pat. No.9,394,098 teaches an adapter collar which can purportedly function as asafety shield in the event of overpressurization and rupture. But thisattempt adds complexity and additional leakage pathways. And thisadapter collar may be ineffective in the case of rupture. U.S. Pat. Nos.3,074,602; 3,292826; 3,372,827 and 3,815,534 teaches score lines and apressure relief valve for an aerosol can. But these attempts in the artrely upon precise tolerances and precision manufacture to properly workrelieve pressure in the event of overpressurization. Such tolerances maybe difficult to maintain in high speed production.

Accordingly, it is an object of this invention to provide an aerosoldispenser which minimizes occurrences of rupture in the event ofoverpressurization, through integral venting using the valve cup.

SUMMARY OF THE INVENTION

In one embodiment the invention comprises an aerosol dispenser fordispensing a product therefrom and having a longitudinal axis. Theaerosol dispenser comprises an outer container having an open top with acrimp ring therearound, the crimp ring having an upper surface and alower surface opposed thereto, the upper surface and the lower surfacebeing joined by an outer surface, an inside diameter surface beingopposed to the outer surface, a shoulder disposed in spaced relationshipbelow the crimp ring, a lower neck portion depending from the crimp ringto the shoulder, sidewalls depending below the shoulder, a closed endbottom joined to the sidewalls, a valve cup joined to the crimp ring, avalve joined to the valve cup for dispensing product from the outercontainer, a product delivery device disposed in the outer container,propellant disposed in the outer container and in operable relationshipwith the product delivery device, the valve cup having a platformdefining a hole therethough to longitudinally receive a valve stemtherein, an outer wall joined to the platform and depending radiallyoutward of the crimp ring outer surface, and a crimp wall joined to theouter wall and clinched underneath the crimp ring lower surface, and atleast one hole or vent disposed in the valve cup outer wall suitable torelieve a gas therethrough.

In one embodiment the invention comprises a valve cup for clinching to acrimp ring of an outer container for an aerosol dispenser, the valve cuphaving a longitudinal axis and a central platform defining a holetherethough to longitudinally receive a valve stem therein, an outerwall joined to the platform and depending therefrom, and a crimp walljoined to the outer wall and being clinchable underneath a crimp ring,and at least one hole disposed in and extending through the valve cupouter wall and being suitable to relieve a gas therethrough.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A is a side elevational view of an aerosol dispenser according tothe present invention.

FIG. 1B is a fragmentary vertical sectional of a representative valvecup, valve and dip tube without being clinched to a crimp ring.

FIG. 1C is fragmentary vertical sectional of a representative valve cupwith a valve therein and being clinched to a crimp ring.

FIG. 2A is a side elevational sectional view of an aerosol dispenserhaving a collapsible bag.

FIG. 2B is a side elevational sectional view an aerosol dispenser havinga dip tube.

FIG. 3 is a fragmentary perspective view of an outer container for theaerosol dispenser of the claimed invention having a fragmentary explodedgasket and an exploded sectional valve cup, the gasket being shown inphantom in position in the valve cup.

FIGS. 4A-4D are drawn to scale and taken from FIG. 3. The vents in FIGS.4A-4D are shown in double cross hatch.

FIG. 4A is a fragmentary enlarged view of a crimp ring having axialvents on the outer surface.

FIG. 4B is a fragmentary enlarged view of a crimp ring having axialvents on the inner surface.

FIG. 4C is a fragmentary enlarged view of a crimp ring having axialvents on the outer surface and lower surface.

FIG. 4D is a fragmentary enlarged view of a crimp ring having axialvents on the outer surface, radial vents on the lower surface lowersurface and inner surface, and further having a circumferential ventbridging the axial and radial vents, respectively vents on both theouter surface and lower surface and a circumferential vent bridging theaxial vents on the inner surface.

FIGS. 5A1-8C are drawn to scale.

FIG. 5A1 is a perspective view of a valve cup having four equally spacedand equally sized vent holes and a valve.

FIG. 5A2 is a side elevational view of the valve cup and valve stem ofFIG. 5A1.

FIG. 5A3 is a sectional view of the valve cup and valve stem of FIG.5A2.

FIG. 5A4 is an enlarged fragmentary view taken from FIG. 5A3.

FIG. 5A5 is a top plan view of the valve cup of FIG. 5A1.

FIG. 5B1 is a perspective view of a valve cup having irregularly spacedand unequally sized vent holes with a valve.

FIG. 5B2 is a side elevational view of the valve cup and valve stem ofFIG. 5B1.

FIG. 5B3 is a sectional view of the valve cup and valve stem of FIG.5B2.

FIG. 5B4 is an enlarged fragmentary view taken from FIG. 5B3.

FIG. 5B5 is a top plan view of the valve cup of FIG. 5B1.

FIG. 6A is a top perspective view of a valve cup according to thepresent invention having radially inward fluted vents.

FIG. 6B is a bottom perspective view of the valve cup of FIG. 6A havingthe crimp wall omitted for clarity.

FIG. 6C is a side elevational view of the valve cup of FIG. 6A.

FIG. 6D is a vertical sectional view of the valve cup of FIG. 6C.

FIG. 6E is an enlarged fragmentary view taken from FIG. 6D.

FIG. 6F is a top plan view of the valve cup of FIG. 6A.

FIG. 7A is a top perspective view of a valve cup according to thepresent invention having radially outward fluted vents.

FIG. 7B is a bottom perspective view of the valve cup of FIG. 7A havingthe crimp wall omitted for clarity.

FIG. 7C is a side elevational view of the valve cup of FIG. 7A.

FIG. 7D is a vertical sectional view of the valve cup of FIG. 7C.

FIG. 7E is an enlarged fragmentary view taken from FIG. 7D.

FIG. 7F is a top plan view of the valve cup of FIG. 7A.

FIG. 8A is a top perspective view of a simplified valve cup according tothe present invention and not having a platform or inner skirt wall.

FIG. 8B is a bottom perspective view of the valve cup of FIG. 8A havingthe crimp wall omitted for clarity.

FIG. 8C is a vertical sectional view of the valve cup of FIG. 8A.

FIG. 9 is a vertical sectional view of a simplified valve cup accordingto the present invention having only a crimp wall, outer wall andplatform.

DETAILED DESCRIPTION OF THE INVENTION

Referring to FIGS. 1A-1C, an aerosol dispenser 20 is shown. The aerosoldispenser 20 comprises a pressurizeable outer container 22 usable forsuch a dispenser. The outer container 22 may comprise plastic or metal,as are known in the art. The outer container 22 has both product 40 andpropellant 42 disposed therein at the point of use.

The outer container 22 has an opening with a valve cup 26 thereintherein. A user activated dispensing valve 28 may be disposed in thevalve cup 26. A product delivery device may be joined to the valve cup26. Propellant 40 may be disposed between the outer container 22 and theproduct delivery device. The product 42 and propellant 40 may beseparately dispensed or may be dispensed together.

The aerosol dispensers 20, and components thereof, may have alongitudinal axis LA, and may optionally be axi-symmetric with a roundcross section. Alternatively, the outer container 22, a product deliverydevice therein, a dispensing valve 28, etc., may be eccentric and have asquare, elliptical or other cross section.

The outer container 22 may have an opening. The opening is typically atthe top of the pressurizeable container 22 when the pressurizeablecontainer 22 is in its-in use position. The opening defines a neck 24,to which other components may be sealed. The neck 24 has a perimeter24P, which defines the outside of the neck 24. The perimeter 24P of theneck 24 may have at least one vent 25, and optionally a plurality ofvents 25. Optionally the neck 24 may be crystallized.

The top of the neck 24 may have a crimp ring 24CR thereon. The crimpring 24CR extends radially outwardly from the neck 24 below. A metalvalve cup 26 may be clinched to the crimp ring 24CR in known fashion. Agasket 24G may be disposed between the top of the crimp ring 24CR andthe valve cup 26.

The valve cup 26 may be integral and formed from a single piece of metalcomprising plural contiguous and annular walls. Alternatively, the valvecup 26 may comprise plastic, or any material suitable for forming aroundor welding to the crimp ring 24CR. Each wall of the valve cup 26 hasopposed inner and outer surfaces, the inner surfaces generally facingdownward or towards the longitudinal axis LA.

Referring to FIGS. 1A, 1B, 1C and 3, the valve cup 26 may have a centerhole, to allow for a valve stem the longitudinally move therethrough.Radially outward from and adjacent the hole is an annular platform 126.Adjacent, radially outward from and contiguous the platform 126 is anannular inner skirt wall 127. Adjacent, radially outward from andcontiguous the inner skirt wall 127 is an annular bottom wall 128.Adjacent, radially outward from and contiguous the bottom wall 128 is anannular outer skirt wall 129.

Preferably the outer skirt wall 129 is spaced away from the insidediameter surface 241 of the neck 24 to allow for ease of assembly.Adjacent, radially outward from and contiguous the outer skirt wall 129is an annular top wall 130. The inner surface of the top wall 130 sealsagainst the gasket 24G. Adjacent, radially outward from and contiguousthe top wall 130 is an annular outer wall 131. The inner surface of theouter wall 131 seals against the outer surface 24CRO of the crimp ring24CR. Adjacent, radially outward from and contiguous the outer wall 129is an annular crimp wall 132. The crimp wall 132 engages the lowersurface 24CRL of the crimp ring 24CR to clamp the valve cup 26 in place.The walls 126, 127, 128, 129, 130, 131, 132 are shown in concentric,parallel and orthogonal relationships, although the invention is not solimited. Any suitable angular relationship may be used.

One of skill will recognize than not all of the walls described aboveneed to be present for a valve cup 26 according to the present inventionto be viable. In simplified embodiment, the valve cup 26 may simply havea platform 126 with a hole therethrough. The hole slidably,longitudinally and/or translationally receive a valve 28, andparticularly a valve stem therethrough. Radially outward of and directlyor indirectly joined to the platform 126 is the outer wall. 131. Theouter wall 131 depends downwardly from the platform 126. A crimp wall132 is directly or indirectly joined to the outer wall 131. The crimpwall 132 is clinched under the crimp ring 24CR, radially inwardly, tohold the valve cup 26 in place.

The annular outer wall 131 may be perforate. By perforate it is meantthat the outer wall 131 is gas permeable. Gas permeability is attainedby one or more circumferentially spaced holes 135 through the outer wall131. The holes 135 allow for exhausting of propellant 40 and/or product42 therethrough which escapes past the gasket 24G to ambient. Likewise,the crimp wall 132 may be similarly perforate.

The holes 135 may be longitudinally centered, or intercept the crimpwall 132. The holes 135 may be equally or unequally sized, equally orunequally circumferentially spaced, and equally or unequallylongitudinally disposed. For the system described herein, three to 15spaced holes 135, having a diameter of 0.3 mm to 1 mm are believed to besuitable and particularly four holes equally spaced at 90 degrees andhaving a diameter of 0.8 mm is believed suitable.

Recycling class 1 thermoplastic elastomer [TPE] may be selected for thegasket 24G. The TPE material may be selected to be resistant to thepropellant 40 and/or product 42 desired for use. A hydrophilic TPE-Ebased compound formulated to provide adhesion to PET and chemicalresistance to silicone oil may be used as one or more components in theaerosol dispenser 20. Class 1 TPE material sold by Kraiburg TPE GmbH &Co KG of Waldkraiburg, Germany under the name Hcc8791-52 may besuitable.

A dispensing valve 28, in turn, may be disposed within the valve cup 26.The dispensing valve 28 provides for retention of product 42 within theaerosol dispenser 20 until the product 42 is selectively dispensed by auser. The product 42 may be dispensed through a dip tube 56 or from abag 55, as is known in the art.

The dispensing valve 28 may be selectively actuated by an actuator 29. Asuitable subcombination 21 may comprise the outer container 22, valvecup 26, dispensing valve 28, and any propellant 40 therein. The outercontainer 22, and valve 28 according to the present invention may beentirely polymeric and particularly entirely Stream 1 as defined by theSociety of Plastics Engineers.

Selective actuation of the dispensing valve 28 allows the user todispense a desired quantity of the product 42 on demand. Illustrativeand nonlimiting products 42 for use with the present invention mayinclude shave cream, shave foam, body sprays, body washes, perfumes,cleansers, air fresheners, astringents, foods, paints, etc.

Referring to FIGS. 2A and 2B, inside the outer container 22 may be aproduct delivery device. The product delivery device may comprise acollapsible bag 55 as shown in FIG. 2A. The collapsible bag 55 may bemounted in sealing relationship to the neck 24 of the container and/orto the dispensing valve 28. This arrangement is known in the art as abag-on-valve. The collapsible bag 55 may hold product 42 therein, andprevent intermixing of such product 42 with propellant 40. Thepropellant 40 may be stored outside the collapsible bag 55, and insidethe outer container 22.

The collapsible bag 55 may expand upon being charged with product 42.Such expansion decreases the available volume inside the outer container22. Decreasing the available volume increases the pressure of anypropellant 40 therein according to Boyles law.

The product delivery device may alternatively or additionally comprise adip tube 56 as shown in FIG. 2B. The dip tube 56 extends from a proximalend sealed to the dispensing valve 28. The dip tube 56 may terminate ata distal end juxtaposed with the bottom of the outer container 22. Thisembodiment provides for intermixing of the product 42 and propellant 40.Both are co-dispensed in response to selective actuation of thedispensing valve 28 by a user. Again, insertion of product 42 and/orpropellant 40 into the outer container 22 increases pressure thereinaccording to Boyles law. The product delivery device may alternativelycomprise a piston as described in commonly assigned US publication2016/0368633.

The outer container 22 may comprise a plastic pressurizeable container.The plastic may be polymeric, and particularly comprise PET. Thedispensing valve 28, and optional valve cup 26 may be welded to the neck24 of the outer container 22, as discussed below. The valve cup 26 maybe clinched to the neck 24 in known fashion.

Any number of known valve assemblies 28 may be usable with the presentinvention. One suitable and non-limiting example, is shown. A suitabledispensing valve 28 may be made according to the teachings of commonlyassigned publications 2010/0133301A1 and/or 2010/0133295A1, and forms nopart of the claimed invention.

The pressurizeable container may further include a propellant 40. Thepropellant 40 may be disposed between the outer container 22 and theproduct delivery device. Alternatively propellant 40 may be disposed inthe outer container 22 and/or the collapsible bag 55. Typically thepressure in the outer container 22 is greater than the pressure in thecollapsible bag 55, so that product 42 may be dispensed from within thebag. If a dip tube 56 is selected for the product delivery device, thepropellant 40 and product 42 may be intermixed, and thus co-dispensed.The pressure of the propellant 40 within the outer container 22 providesfor dispensing of the product 42/co-dispensing of product 42/propellant40 to ambient, and optionally to a target surface. The target surfacemay include a surface to be cleaned or otherwise treated by the product42, skin, etc. Such dispensing occurs in response to the user actuatingthe dispensing valve 28.

Examining the components in more detail, the product delivery device maycomprise a flexible, collapsible bag 55. The pressure boundary for thepropellant 40 is formed, in part, by the collapsible bag 55. Or theproduct delivery device may comprise a dip tube 56. In eitherembodiment, the pressure boundary for the propellant 40 is formed, inpart by the underside of the dispensing valve 28 when the valve 28 isclosed.

If desired, the outer container 22, dispensing valve 28, dip tube 56and/or collapsible bag 55 may be polymeric. By polymeric it is meantthat the component is formed of a material which is plastic, comprisespolymers, and/or particularly polyolefin, polyester or nylons. Thus, theentire aerosol dispenser 20 or, specific components thereof, may be freeof metal, allowing exposure to microwave energy.

The valve cup 26 may comprise ductile and formable metal such as lowcarbon steel or aluminum. The valve cup 26 may be stamped and clinchedin known fashion.

If desired, the outer container 22, collapsible bag 55, and/or dip tube56, may be transparent or substantially transparent. If both the outercontainer 22 and a collapsible bag 55 used as the product deliverydevice are transparent, this arrangement provides the benefit that theconsumer knows when product 42 is nearing depletion and allows improvedcommunication of product 42 attributes, such as color, viscosity, etc.Also, labeling or other decoration 57 of the container 22 may be moreapparent if the background to which such decoration is applied is clear.Alternatively or additionally, the outer container 22, collapsible bag55, etc. may be transparent and colored with like or different colors.

The outer container 22 may define a longitudinal axis LA of the aerosoldispenser 20. The outer container 22 may be axisymmetric as shown, or,may be eccentric. While a round cross-section is shown, the invention isnot so limited. The cross-section may be square, elliptical, irregular,etc. Furthermore, the cross section may be generally constant as shown,or may be variable. If a variable cross-section is selected, the outercontainer 22 may be barrel shaped, hourglass shaped, or monotonicallytapered.

The outer container 22 may range from 6 to 40 cm in height, taken in theaxial direction and from 4 to 60 cm in diameter if a round footprint isselected. The outer container 22 may have a volume ranging from 50 or115 cc to 1000 cc exclusive of any components therein, such as a productdelivery device. The outer container 22 may be injection stretch blowmolded. If so, the injection stretch blow molding process may provide astretch ratio of greater than 8, 8.5, 9, 9.5, 10, 12, 15 or 20.

The outer container 22 may sit on a base. The base is disposed on thebottom of the outer container 22 and of the aerosol dispenser 20.Suitable bases include petaloid bases, champagne bases, hemispherical orother convex bases used in conjunction with a base cup. Or the outercontainer 22 may have a flat base with an optional punt.

A punt is a concavity in the bottom of the container and extendingtowards the neck 24 of the container. A punt is distinguishable from ageneral concavity in the bottom of a container, as a punt has a smallerdiameter than is defined by the footprint of the bottom of thecontainer. The punt may be axisymmetric about the longitudinal axis LA.The vertex of the punt may be coincident the longitudinal axis LA. Theouter container 22 sidewall also defines a diameter.

The plastic outer container 22 preferably does not creep under pressuresranging from 100 to 970 kPa, and having a sidewall thickness less than0.5 mm. The outer container 22 may be pressurized to an internal gagepressure of 100 to 970, 110 to 490 or 270 to 420 kPa. A particularaerosol dispenser 20 may have an initial propellant 40 pressure of 1100kPA and a final propellant 40 pressure of 120 kPa, an initial propellant40 pressure of 900 kPA and a final propellant 40 pressure of 300 kPa, aninitial propellant 40 pressure of 500 kPA and a final propellant 40pressure of 0 kPa, etc. The propellant 40 pressurizes the product 42 toa pressure greater than ambient, to provide for delivery from theaerosol dispenser 20.

The aerosol dispenser 20, as presented to a user may have an initialpressure. The initial pressure is the highest pressure encountered for aparticular filling operation, and corresponds to no product 42 yet beingdispensed from the product delivery device. As product 42 is depleted,the outer container 22 approaches a final pressure. The final pressurecorresponds to depletion of substantially all product 42, except forsmall residual, from the product delivery device.

The outer container 22, and all other components, except the TPE gasket24G, and valve cup 26 may comprise, consist essentially of or consist ofPET, PEN, Nylon EVOH or blends thereof to meet DOT SP 14223. Suchmaterials may be selected from a single class of recyclable materials,as set forth above by the SPI.

The neck 24 may be connected to the container sidewall by a shoulder 23.The shoulder 23 may more particularly be joined to the sidewall by aradius. The shoulder 23 may have an annular flat. The neck 24 may have agreater thickness at the top of the outer container 22 than at lowerportions of the neck 24 to provide a differential thickness. Suchdifferential thickness may be accomplished through having an internallystepped neck 24 thickness.

The product 42 may also be inflammable. Flammability, and the absencethereof, may be determined in accordance with the absence of a firepoint per ASTM D 92, Standard Test Method for Flash and Fire Points byCleveland Open Cup Tester, by ASTM E-681 and/or EU A11 test methods.

The propellant 40 may comprise nitrogen, air hydrofluoroolefin andmixtures thereof. Propellant 40 listed in the US Federal Register 49 CFR173.115, Class 2, Division 2.2 are also considered acceptable. Thepropellant 40 may particularly comprise a hydrofluoroolefin, aTrans-1,3,3,3-tetrafluoroprop-1-ene,1-chloro-3,3,3-trifluoroprop-1-ene,(1E), and optionally a CAS number1645-83-6 gas. Suitable propellants 40 are commercially available fromHoneywell International of Morristown, N.J. under the trade namesSOLSTICE® ZE (HFO-1234ze) and SOLSTICE® PF (HFO-1233zd(E)).

If desired, the propellant 40 may be condensable. By condensable, it ismeant that the propellant 40 transforms from a gaseous state of matterto a liquid state of matter within the outer container 22 and under thepressures encountered in use. Generally, the highest pressure occursafter the aerosol dispenser 20 is charged with product 42 but beforethat first dispensing of that product 42 by the user. A condensablepropellant 40 provides the benefit of a flatter depressurization curveas product 42 is depleted during usage.

A condensable propellant 40 provides the benefit that a greater volumeof gas may be placed into the container at a given pressure. Upondispensing of a sufficient volume of product 42 from the space betweenthe outer container 22 and the product delivery device, the condensablepropellant 40 may flash back to a gaseous state of matter.

The pressurizeable container 22 may be charged with an amount of product42 which brings the pressure, as initially presented to the user,sufficient to dispense and substantially deplete the product 42 from theaerosol dispenser 20. The final pressure, after substantially allproduct 42 is depleted, is less than the initial pressure.

Product 42 may be charged into the container through the dispensingvalve 28, as is known in the art. When product 42 is charged into thecontainer, the product 42 increases the pressure of the propellant 40.The increase in propellant 40 pressure occurs due to the increase involume of the collapsible bag 55 if such a bag 55 is used as a productdelivery device. Likewise, the increase in propellant 40 pressure occursdue to the increase in the number of moles of product 42 in the outercontainer 22 if a dip tube 56 is selected. An aerosol dispenser 20 maybe made according to commonly assigned US 2012/0292338A1; US2012/0291911A1; and/or US 2012/0291912A1.

The pressure of the propellant 40 at the end of the first phase ofmanufacture may correspond to the pressure at the end of the usable lifeof the aerosol dispenser 20, herein referred to as the final pressure.The pressure of the propellant 40 at the end of the second phase ofmanufacture may correspond to the pressure as initially presented to theuser.

The propellant 40 may be provided at a pressure corresponding to thefinal pressure of the aerosol dispenser 20 when substantially allproduct 42 is depleted therefrom. The propellant 40 may be charged to apressure of less than or equal to 300, 250, 225, 210, 200, 175 or 150kPa. The propellant 40 may be charged to a pressure greater than orequal to 50, 75, 100 or 125 kPa. The gage pressures cited herein are tobe construed as the initial pressure inside the outer container 22, asmanufactured and prior to first use.

Plural valves 28 may be used with a single outer container 22. Thisarrangement provides the benefit that product 42 and propellant 40, ordisparate products 42, are mixed at the point of use, allowingsynergistic results between incompatible materials. This arrangementalso provides the benefit that delivery of the propellant 40 providesmotive force to the product 42, often resulting in smaller particle sizedistributions. Smaller particle size distributions can be advantageousfor uniform product 42 distribution and minimizing undue wetting.

The aerosol dispenser 20, and particularly the outer container 22thereof, may have a burst pressure of at least 1100 kPa at 54.4 degreesC. and further may have a burst pressure of at least 1650 kPa at 20degrees C. Meeting these burst pressures is believed to avoid the needfor using DOT exemptions.

Referring to FIG. 3, the outer container 22 may have a round crimp ring24CR with an inner diameter oriented towards the longitudinal centerlineLA and an outer diameter opposed thereto. The crimp ring 24CR have bethought of as having three conjoined surfaces, an upper surface 24CRU, alower surface 24CRL opposed thereto, and an outer surface 24CRO joiningthe upper surface 24CRU and lower surface 24CRL. The three surfaces24CRU, 24CRL and 24CRO are shown in parallel and orthogonalrelationships, although the invention is not so limited. Any suitableangular relationship may be used.

The upper surface 24CRU of the crimp ring 24CR typically has two annularbeads 242 to minimize leakage through the gasket 24G. The annular beads242 are optional and form no part of the claimed invention. The uppersurface 24CRU preferably does not form part of the vent 25 claimedherein.

Referring to FIGS. 4A-4D, the outer surface 24CRO of the crimp ring 24CRmay have at least one vent 25. The vent 25 comprises a channel throughthe outer surface 24CRO and between the outer surface 24CRO and thevalve cup 26. The vent 25 is integral with the neck 24, so thatsubsequent steps are not needed to make the vents operational anduseful.

Preferably, the vent 25 extends throughout the entire length of theouter surface 24CRO. This arrangement provides for controlled release ofpressure should overpresurization occur. More specifically, upon overpressurization, the neck 24 may bulge to a barrel shape, causing theupper surface 24CRU to deform concave inwardly. Propellant 42 and/orproduct 40 may the leak past the gasket 24G and be exhausted to ambientoutwardly through the vents 25.

Plural vents 25, equally circumferentially spaced about the perimeter ofthe outer surface 24CRO may be used to provide adequate flow area forthe exhaust. The flow area throttles the exhaust of propellant 42 and/orproduct 40 to safely depressurize the outer container 22.Circumferential spacing of the vents 25 allows for exhaust in the eventdeformation of the neck 24 is eccentric or occurs unevenly. The vents 25are preferably integral with the underlying surface and outer container22.

Optionally, vents 25 may also be disposed on the lower surface 24CRL ofthe crimp ring 24CR. These vents 25 are preferably aligned with thevents 25 on the outer surface 24CRO of the crimp ring 24CR. Preferably,the vents 25 extends throughout the entire length of the lower surface24CRL to provide for adequate venting. These additional and optionalvents 25 provide for venting between the lower surface 24CRL and thevalve cup 26.

Further optionally, vents 25 may also be placed on the inside diametersurface 241 of the neck 24. Such vents 25 preferably extend in thelongitudinal direction to at least the bottom of the valve cup 26adjacent the inside diameter surface 241 of the neck 24. Preferablythese vents 25 do not extend to the shoulder 23 or even the bottom ofthe neck 24 for strength. These additional and optional vents 25 providefor venting between the inside of the neck 24 and the valve cup 26.Again, preferably the

For any of the aforementioned surfaces, i.e. the inner diameter of theneck 24, the upper surface CRU of the crimp ring 24, and lower surface24CRL of the crimp ring 24L, one, two, or preferably at least threeequally spaced vents 25 may be used. Six to 12 vents 25 are believed tobe suitable. The vents 25 may be of constant cross section or variablecross section. The vents 25 may be of equal or unequal size, geometryand flow area. The vents 25 may be equally or unequallycircumferentially spaced. The vents 25 may have any suitable crosssection and hydraulic radius.

Referring particularly to FIG. 4D, optionally a circumferential vent 25may connect the axial vents 25 on the outer surface 24CRU, the axialvents 25 on the inside diameter surface 241 of the crimp ring 24CRU, orthe radial vents on the lower surface 24CRU. Such a circumferential ventprophetically allows cross communication between the aforementionedaxial and radial vents.

Referring generally to FIGS. 4A-4D the vents 25 on the inner diameter ofthe neck 24 and outer surface 24CRO may be axially parallel or skewedrelative to the longitudinal axis LA. The vents 25 on the lower surface25CRL may be radially oriented, or radially skewed, such as spiraloriented. Again, preferably the upper surface 24CRU does not have vents25 therethrough or vents 25 which interrupt the optional annular beads242.

For a crimp ring 24CR having an outer radius of 32 mm, and an aerosoldispenser 20 having typical internal pressures, eight equally spacedvents 25, each having a radial depth of 0.8 millimeters may be used.

Referring to FIGS. 5A1-5A5, the valve cup 26 according to the inventionmay have one or more 135 therethrough. The holes 135 are disposed on theouter wall 130 to allow exhaust of propellant 40 and/or product 42therethrough. The holes 135 may be disposed at any desired axial orcircumferential position on the outer wall 131. The holes 135 mayintercept the crimp wall 132, but preferably do not intercept the topwall 130.

Referring to FIGS. 5B1-5B5, while four holes 135 equallycircumferentially spaced are shown, and axially centered on the outerwall 131 are shown, the invention is not so limited in the embodiment ofFIGS. 5A1-5A5. The holes 135 may be axially or circumferentially spacedanywhere on the outer wall 131 and may intercept both the outer wall 131and crimp wall 132.

Referring particularly to FIGS. 5B1, 5B2 and 5B4, the holes 135 may beaxially stacked as shown in FIG. 5B4. And/or the holes 135 may be round,elongate in the axial direction, the circumferential direction as shownin FIGS. 5B1-5B2. The holes 135 may have any desired polygonal, roundoval shape or other shape as desired.

Referring to FIGS. 6A-6F, the valve cup 26, and particularly the outerwall 131 thereof may be fluted to provide vents 135V. The vents 135V actas and have the geometry of channels and are believed to provide thesame functionality as the holes 135 in the preceding embodiments.Preferably the vents 135 do not intercept the beads 242 on the uppersurface 24CRU of the crimp ring 24CR. The vents 135 preferably extend tothe bottom of the outer wall 131 to allow unimpeded venting.

The vents 135V may be of equal or unequal size, circumferential spacing,cross section and/or hydraulic radius. The vents 135V may be axiallyparallel or skewed relative to the longitudinal axis LA.

The vents 135V may be circumferentially spaced apart and alternatelyspaced apart by radially inwardly oriented ribs 136, providing channelsfor the vents 135V between adjacent ribs 136. The ribs 136 may becircumferentially narrower than the vents 135V to concentrate thecompressive forces on the crimp ring 24CR. This geometry also provides alarger flow area for the vents 135V.

The alternately spaced ribs 136 and vents 135V may further extend to theinner surface of the crimp wall 132 in addition to the vents 135V in theouter wall 131. The ribs 136 and vents 135V disposed on the crimp wall132 may be radially oriented or radially skewed. The vents 135V andholes 135 may be used in combination on the same valve cup 26, in eitheror both of the crimp wall 132 and/or outer wall 131.

Referring to FIGS. 7A-7F, another embodiment having alternately spacedribs 136 and vents 135V is shown. This embodiment has radially outwardlyoriented vents 135V. The geometry provides the benefit ofcircumferentially wider ribs 136. The wider ribs provide the benefit ofgreater contact area when clinching the valve cup 26 to the crimp ring24CR. Also, the radially externally oriented vents 135V may be lessprone to occluding from debris on the outside of neck 24.

Referring to FIGS. 8A-8C, an alternative embodiment of valve cup 26 isshown. This valve cup 26 has a simplified construction relative to theforegoing embodiments, yet retains all of the aforementioned variationsand combinations of holes 135 and vents 135V. This valve cup 26 has abottom wall 128, directly joined to an outboard outer skirt wall 129,which, in turn, is directly joined to an outboard top wall 130, which inturn is directly joined to an outboard outer wall 131, which in turn isdirectly joined to a radially inwardly extending crimp wall 132.

This arrangement has the benefit of eliminating the platform 126 andinner skirt wall 127, conserving material. The embodiment of FIGS. 8A-8Cincludes and subsumes all embodiments previously discussed herein.

Referring to FIG. 9, an alternative embodiment of valve cup 26 is shown.This valve cup 26 has a further simplified construction relative to theforegoing embodiments, yet retains all of the aforementioned variationsand combinations of holes 135 and vents 135V. This valve cup 26 has aplatform 126, which in turn is directly joined to an outboard outer wall131, which in turn is directly joined to a radially inwardly extendingcrimp wall 132.

This arrangement has the benefit of eliminating the bottom wall 128 andinner skirt wall 127, further conserving material. The embodiment ofFIG. 9 includes and subsumes all embodiments previously discussedherein.

The embodiments shown herein are shown to have annular features such asplatform 126, bottom wall 128, top wall 130 and crimp wall 132 which aregenerally perpendicular to the longitudinal axis LA. And the embodimentsshown herein are shown to have annular features such as inner skirt wall127, outer skirt wall 129 and outer wall 131 which are generallyparallel to the longitudinal axis LA. One of skill will recognize theinvention is not so limited. The walls 126, 127, 128, 129, 130, 131 and132 may be skewed relative to each other and/or the longitudinal axis.Concentricity is shown and presumed, although other geometries may befeasible.

The various embodiments disclosed herein are shown to have three walls126, 131 and 132 in the embodiments of FIG. 9, five walls 128, 129, 130,131 and 132 in the embodiments of FIGS. 8A-8C and seven walls 126, 127,128, 129, 130, 131 and 132 in the embodiments of FIGS. 3-7F. It isunderstood that all three wall embodiments 126, 131 and 132 areinclusive of all embodiments have four, five or more walls 128, 129,130, 131 and 132 and all five wall embodiments are inclusive of allembodiments having five, six seven or more walls 126, 127, 128, 129,130, 131 and 132.

In various embodiments, the invention may be described according to thefollowing paragraphs.

-   -   A. An aerosol dispenser 20 for dispensing a product 42 therefrom        and having a longitudinal axis LA, said aerosol dispenser 20        comprising:    -   an outer container 22 having an open top with a crimp ring 24CR        therearound, said crimp ring 24CR having an upper surface 24CRU        and a lower surface 24CRL opposed thereto, said upper surface        24CRU and said lower surface 24CRL being joined by an outer        surface 24CRO, an inside diameter surface being opposed to said        outer surface 24CRO,    -   a shoulder 23 disposed in spaced relationship below said crimp        ring 24CR,    -   a lower neck 24 portion depending from said crimp ring 24CR to        said shoulder 23,    -   sidewalls depending below said shoulder 23,    -   a closed end bottom joined to said sidewalls,    -   a valve cup 26 joined to said crimp ring 24CR,    -   a valve joined to said valve cup 26 for dispensing product 42        from said outer container 22,    -   a product 42 delivery device disposed in said outer container        22,    -   propellant 40 disposed in said outer container 22 and in        operable relationship with said product 42 delivery device,    -   said valve cup 26 having a platform 126 defining a hole 135        therethough to longitudinally receive a valve stem therein, an        outer wall 131 joined to said platform 126 and depending        radially outward of said crimp ring 24CR outer surface 24CRO,        and a crimp wall 132 joined to said outer wall 131 and clinched        underneath said crimp ring 24CR lower surface 24CRL, and    -   at least one hole 135 or vent 135V disposed in said valve cup 26        outer wall 131 suitable to relieve a gas therethrough.    -   B. An aerosol dispenser 20 according to paragraph A comprising        at least three holes 135 equally circumferentially spaced about        said outer wall 131.    -   C. An aerosol dispenser 20 according to paragraphs A and B        comprising at least three holes 135 equally circumferentially        spaced about said outer wall 131 and further comprising a        plurality of holes 135 through said valve cup 26 crimp wall 132.    -   D. An aerosol dispenser 20 according to paragraphs A, B and C        comprising at least four holes 135 internal to and equally        circumferentially spaced about said outer wall 131.    -   E. An aerosol dispenser 20 according to paragraphs A, B, C and D        wherein said product 42 delivery device comprises a dip tube 56.    -   F. A valve cup 26 for clinching to a crimp ring 24CR of an outer        container 22 for an aerosol dispenser 20, said valve cup 26        having a longitudinal axis LA and a central platform 126        defining a hole 135 therethough to longitudinally receive a        valve stem therein, an outer wall 131 joined to said platform        126 and depending therefrom, and a crimp wall 132 joined to said        outer wall 131 and being clinchable underneath a crimp ring        24CR, and at least one hole 135 disposed in and extending        through said valve cup 26 outer wall 131 and being suitable to        relieve a gas therethrough.    -   G. A valve cup 26 according to paragraph F having a plurality of        circumferentially spaced holes 135 through said outer wall 131.    -   H. A valve cup 26 according to paragraphs F and G having a        plurality of equally circumferentially spaced holes 135 through        said outer wall 131.    -   I. A valve cup 26 according to paragraphs F, G and H having a        plurality of equally circumferentially spaced and equally        axially spaced holes 135 through said outer wall 131.    -   J. A valve cup 26 according to paragraphs F, G, H and I further        comprising at least one hole 135 through said crimp wall 132.    -   K. A valve cup 26 according to paragraphs F, G, H, I and J        further comprising a plurality of circumferentially spaced holes        135 through said crimp wall 132.    -   L. A valve cup 26 according to paragraphs F, G, H, I, J and K        wherein said holes 135 are round and have a diameter ranging        from 0.6 mm to 1.6 mm    -   M. A valve cup 26 for clinching to a crimp ring 24CR of an outer        container 22 for an aerosol dispenser 20, said valve cup 26        having a longitudinal axis LA and a central platform 126        defining a hole 135 therethough to longitudinally receive a        valve stem therein, an outer wall 131 joined to said platform        126 and depending therefrom, and a crimp wall 132 joined to said        outer wall 131 and being clinchable underneath a crimp ring        24CR, and at least one vent 135V disposed inside said valve cup        26 outer wall 131 and being suitable to relieve gas        therethrough.    -   N. A valve cup 26 according to paragraph M comprising a        plurality of alternately circumferentially spaced vents 135V and        ribs 136 disposed about and within said outer wall 131, said        ribs 136 extending radially inwardly of said outer wall 131.    -   O. A valve cup 26 according to paragraphs M and N comprising a        plurality of alternately equally circumferentially spaced vents        135V and ribs 136 disposed about and within said outer wall 131,        said ribs 136 extending radially inwardly of said outer wall        131.    -   P. A valve cup 26 according to paragraphs M, N and O comprising        a plurality of alternately circumferentially spaced axially        parallel vents 135V and axially parallel ribs 136 disposed about        and within said outer wall 131, said ribs 136 extending radially        inwardly of said outer wall 131.    -   Q. A valve cup 26 according to paragraphs M, N, O and P        comprising a plurality of alternately equally circumferentially        spaced vents 135V and ribs 136 disposed about and within said        outer wall 131, said ribs 136 extending radially inwardly of        said outer wall 131, each said vent 135V having a vent 135V        circumferential width and each said rib 136 having a rib 136        circumferential width, said vent 135V circumferential width        being greater than said rib 136 circumferential width.    -   R. A valve cup 26 according to paragraphs 13 comprising a        plurality of alternately circumferentially spaced vents 135V and        ribs 136 disposed about and within said outer wall 131, said        ribs 136 extending radially inwardly of said outer wall 131,        said valve cup 26 comprising from 10 to 20 equally spaced ribs        136.    -   S. A valve cup 26 according to paragraphs 18 wherein said ribs        136 collectively subtend from 35 to 65 degrees.    -   T. A valve cup 26 according to paragraphs 13 comprising a        plurality of alternately circumferentially spaced vents 135V and        ribs 136 disposed about and within said outer wall 131, said        ribs 136 extending radially inwardly of said outer wall 131 and        a plurality of alternately circumferentially spaced vents 135V        and ribs 136 disposed about and within said crimp wall 132, said        ribs 136 extending radially outward from said longitudinal axis        LA.

The dimensions and values disclosed herein are not to be understood asbeing strictly limited to the exact numerical values recited. Instead,unless otherwise specified, each such dimension is intended to mean boththe recited value and a functionally equivalent range surrounding thatvalue. For example, a dimension disclosed as “40 mm” is intended to mean“about 40 mm” and a pressure disclosed as “about 1100 kPa” is intendedto include 1103.2 kPa.

Every document cited herein, including any cross referenced or relatedpatent or application, is hereby incorporated herein by reference in itsentirety unless expressly excluded or otherwise limited. The citation ofany document is not an admission that it is prior art with respect toany invention disclosed or claimed herein or that it alone, or in anycombination with any other reference or references, teaches, suggests ordiscloses any such invention. Further, to the extent that any meaning ordefinition of a term in this document conflicts with any meaning ordefinition of the same term in a document incorporated by reference, themeaning or definition assigned to that term in this document shallgovern. All limits shown herein as defining a range may be used with anyother limit defining a range. That is the upper limit of one range maybe used with the lower limit of another range, and vice versa.

While particular embodiments of the present invention have beenillustrated and described, it would be obvious to those skilled in theart that various other changes and modifications can be made withoutdeparting from the spirit and scope of the invention. It is thereforeintended to cover in the appended claims all such changes andmodifications that are within the scope of this invention.

What is claimed is:
 1. An aerosol dispenser for dispensing a producttherefrom and having a longitudinal axis, the aerosol dispensercomprising: an outer container having an open top with a crimp ringtherearound, the crimp ring having an upper surface and a lower surfaceopposed thereto, the upper surface and the lower surface being joined byan outer surface, an inside diameter surface being opposed to the outersurface, a shoulder disposed in spaced relationship below the crimpring, a lower neck portion depending from the crimp ring to theshoulder, sidewalls depending below the shoulder, a closed end bottomjoined to the sidewalls, a valve cup joined to the crimp ring, a valvejoined to the valve cup for dispensing product from the outer container,a product delivery device disposed in the outer container, propellantdisposed in the outer container and in operable relationship with theproduct delivery device, the valve cup having a platform defining a holetherethough to longitudinally receive a valve stem therein, a top walljoined to the platform and disposed on the crimp ring upper surface; anouter wall joined to the top wall and depending radially outward of thecrimp ring outer surface, and a crimp wall joined to the outer wall andclinched underneath the crimp ring lower surface, and at least one holedisposed in the valve cup outer wall suitable to relieve a gastherethrough, wherein the at least one hole does not intercept the topwall.
 2. An aerosol dispenser according to claim 1 comprising at leastthree holes equally circumferentially spaced about said outer wall. 3.An aerosol dispenser according to claim 1 comprising at least threeholes equally circumferentially spaced about said outer wall and furthercomprising a plurality of holes through said valve cup crimp wall.
 4. Anaerosol dispenser according to claim 1 comprising at least four holesinternal to and equally circumferentially spaced about said outer wall.5. The aerosol dispenser according to claim 1 wherein the productdelivery device comprises a dip tube.
 6. The valve cup according toclaim 1 having a plurality of circumferentially spaced holes through theouter wall.
 7. The valve cup according to claim 6 wherein the holes areround and have a diameter ranging from 0.6 mm to 1.6 mm.
 8. The aerosoldispenser according to claim 1, comprising a gasket disposed between thetop wall and the crimp ring upper surface.